My Carbon Styleswap Cover (BLOG)

  1. Maximus Decimus Meridius
    Marshmallow Moderator Mar 29, 2015

    Maximus Decimus Meridius , Mar 29, 2015 :

    This is my CONTEST-link:
    Please have a look!
    Read-n-participate-n-Enjoy or be gone

    Intro: Laminating a cover with carbon.
    Carbon fiber reinforced object in combination with resin is mainly for its special materialproperties. Due to its weight and rigidness its greatly used in premium branches like the automotive branche (or other transportation types: Nautical/off-shore or aerospace, whatever)
    To make something out of carbon/kevlar i think it will require much time, skill, patience and effort to fabricate CFR (carbon reinforced fibre) items. There are many different techniques to reinforce an object. Aramid/Kevlar/glassfibre/even bamboo, etc etc. In a matrix of epoxy or other type of medium.

    For example: a GENUINE full carbon car part
    Schermafbeelding 2015-03-27 om 23.43.42.png
    Costs $100-500
    Custom $500+ (estimate?)

    The StyleSwap next to an i5 testcover! Current state: second layer (of 3) of resin applied, lots of bubbles

    Not only the effort (&knowledge &skills) you put into the item, but also the basic materials isn't exactly cheap. This is why it is quite a prestige material. Because of this fact it also became an esthetic thing. People “skin” their cars (and what not) with nylonsheets, so called carbon-look wraps.

    Schermafbeelding 2015-03-27 om 23.40.39.png
    A type of dye with a "carbon-look" pattern.

    3M's Carbon Di-Noc

    Although i like the customization, it doesn’t really have that “3d-look” i’m looking for. Or there isn’t somewhat a depth or shine to it, so in my opinion it doesnt look like the real deal because its just not real carbon.

    Why OnePlus? WHYYYYY?
    After some research...

    I found a technique called CARBON LAMINATION. It involves GENUINE carbon, on the other hand, this type of application with CFR will loose lots of important properties. But i hope it will give us a GENUINE LOOK :) , cuz thats all i need. (without loss of other functions)

    Please keep an eye on this thread, make sure you read the SPOILERS. If @OnePlus won’t sell me a Carbon StyleSwap, i’m going for their NeverSettle slogan, and make a carbon styleswap cover myself!
    Lets see where this ends. Initially i wanted to wait for starting this thread. But its also a birthday thread to lnx . HBD!
    Last edited: Jul 31, 2015

  2. Maximus Decimus Meridius
    Marshmallow Moderator Mar 29, 2015

    Maximus Decimus Meridius , Mar 29, 2015 :

    Testing on an iPhone5 backcover
    I dont know how this weird cover came into my house :), nobody's using it, so great testing material: It's supposed to be the same type of plastic, slightly thicker than the Sandstone (thus a bit more "rigid).

    The i5 back cover with some glue of the flap/leatherskin

    Sanded + a Cyanogen sticker cuz bored :)

    Applying the gelcoat for adhesive under layer

    Lets half-cure it till it gets "sticky" (for draping C-sheet)

    The carbon sheet. With some side-cuts to improve flexibility :)

    Next step: Applying carbon sheet over sticky gelcoat... After curing the next resin layer may be applied!
    Just applied the (quite sturdy) carbon sheet. And trimmed it a bit.

    [Now i'm missing a picture]: So after curing the carbon sheet onto the GelCoat, i applied a layer of resin. And used pressure as equal as possible with a peelply (Nylon). This technique supposed to remove the bubbles out of the resin layer, and makes the layer look like sandpaper (see next pic)

    In this pic you can see the rough surface of the first outer layer (hotcoat). It isn't fully covered, but thats ok. I also trimmed the rest of the (already hardened) carbon sheet.

    le paint et le wild carbonne appears underneath

    Oh nooooo! Airbubbles! Will they go away?

    Taken with an OPO-FLASH, reflection is shown and takes the focus a bit out of the many bubbles. At thick regions the 3d-effect is already amazing!

    Tagwords: carbon CFR fibre reinforced epoxy laminating resin mould 3d 3M di-noc kevlar styleswap cover
    Last edited: Apr 1, 2015

    Tobikage, addam, ChrisTerp and 12 others like this.
  3. Kyngo
    Gingerbread Mar 29, 2015

  4. Maximus Decimus Meridius
    Marshmallow Moderator Mar 29, 2015

    Maximus Decimus Meridius , Mar 29, 2015 :
    Now: the Sandstone black Styleswap cover!

    I was ready to do the SandstoneBlack. I got it second hand somewhere.

    My plan is to sand it down. Then the Gelcoat (adhesive layer), carbon sheet (twill weaved .24mm), add resin layer with peel ply sheet. And looking for some next steps to give it a nice look.

    Look at the gelcoat its shiny! (ugh, the smell!)

    Fitting and placing the sheet tightly onto the cover :)

    While curing, i added another layer on the iCover. Its soooooo smooth. :)

    After curing the resin layer with the peelply:
    (Airbubblee?) The peelply was kinda folded and couldnt find a better piece, so i took the chance. It should be cured enough by now...

    Pulling off the peelply nylon sheet... It looks okay beneath it.

    Can't stand the airbubble that developed! But it shouldnt be that of a problem because there are many more layers to come.
    Although... This structure looks also very classy (if without bubble)

    And now, the iCover and StyleSwap are covered with an extra layer of resin. It already looks shiny!

    Well look at that!!!! (Oh no, the resin should be a bit more thick, and it looks like it flows to the (sloping) sides. Ohhh well, going to polish it later on.

    Next step will be curing this layer. And determine how thick it is.
    Last edited: Jul 17, 2015

  5. Dembe
    Froyo Mar 29, 2015

  6. badger906
    Jelly Bean Mar 29, 2015

    NightHawk94, addam, Zinnow and 6 others like this.
  7. badger906
    Jelly Bean Mar 29, 2015

  8. EpicSwirly
    Mar 29, 2015

    EpicSwirly , Mar 29, 2015 :
    You're starting to sound like our favorite company...lol.

    t4ww4b, addam, Jeffrey98 and 9 others like this.
  9. dwong
    Ice Cream Sandwich Mar 29, 2015

  10. Ceasedd
    Marshmallow Mar 29, 2015

    Ceasedd , Mar 29, 2015 :
    I'd like some more pics of that beauty please :) *edit: nevermind :( you haven't made it yet :(

  11. lnxpro
    Jelly Bean Mar 29, 2015

  12. Toulouse
    KitKat Mar 29, 2015

  13. EpicSwirly
    Lollipop Mar 29, 2015

  14. feluda
    Lollipop Mar 29, 2015

    addam, lnxpro, Ceasedd and 1 other person like this.
  15. feluda
    Lollipop Mar 29, 2015

    feluda , Mar 29, 2015 :
    Can't you take a clear case and carbon laminate it ?

    addam, lnxpro, Ceasedd and 1 other person like this.
  16. risky1301
    Lollipop Mar 29, 2015

  17. AsadP
    KitKat Mar 29, 2015

    AsadP , Mar 29, 2015 :
    Looks very amazing and sexy.

    I currently have my dbrand skin applied.. So sleek.

  18. sponge_dork
    Jelly Bean Mar 30, 2015

  19. lnxpro
    Jelly Bean Mar 30, 2015

    lnxpro , Mar 30, 2015 :
    Thank you :D
    Me too +99999

  20. dhaugru
    KitKat Mar 30, 2015

    dhaugru , Mar 30, 2015 :
    Would buy as long as it doesn't add too much bulk from original cover. Looks nice!